Well drilling system

ABSTRACT

A well drilling system includes a torque drive system; a tubular string positioned below and rotated by the torque drive system; a pipe handler and back-up clamp assembly positioned between the torque drive system and the tubular string for coupling with and supporting one end of the tubular string; at least one internal blow-out preventer (IBOP) valve positioned between the torque drive system and the back-up clamp assembly; and a measurement device for measuring parameters of drilling, casing running or tubular make-up and break-out operations. The measurement device measures parameters below the IBOP valve so that parameters such as internal fluid pressures may be monitored even when the IBOP valve is closed. The measurement device is separate from the IBOP valve and is connected above the back-up clamp assembly and tubular string.

RELATED APPLICATIONS

The present application is a non-provisional patent application and claims priority benefit, with regard to all common subject matter, of earlier-filed U.S. provisional patent application titled, “INTEGRATED VALVE-SENSOR SYSTEM WITH DATA PROCESSING”, Ser. No. 62/619,244 and filed Jan. 19, 2018; and U.S. provisional patent application titled, “INTEGRATED VALVE-SENSOR SYSTEM WITH DATA PROCESSING”, Ser. No. 62/565,685 and filed Sep. 29, 2017, both of which are incorporated by reference in their entireties into the present application.

BACKGROUND

Well drilling systems are used to drill well bores for oil, gas, geothermal, or water wells. Such systems typically include a tubular string with a drill bit and a torque drive system for rotating the tubular string so as to drive the drill bit into a ground surface. These systems also often include a fluid pumping system for pumping water or other drilling fluids through the tubular string and back up the well bore to remove drill cuttings from the well bore. Tubular connections are made up to add tubulars and lengthen the drill, landing, or casing string to reach the desired depth. The wellbore's integrity is typically secured by running casing strings into the wellbore. One or more internal blow-out preventer (IBOP) valves are typically positioned below the torque drive system for preventing uncontrolled release of fluids or gases through the well drilling system when high well pressures are experienced in the well bore.

During drilling operations, casing running operations, tubular make-up and break-out operations, and other wellbore construction operations, it is desirable to measure and monitor certain parameters such as the torque, turns, tension, compression, rpm, internal tubular fluid pressures, temperature, vibration, and other parameters.

During casing running operations, it is highly desirable to monitor the casing makeup parameters such as torque, turns, tension, rpm, and other parameters.

These parameters have conventionally been measured indirectly and/or at locations remote from the tubular string, but such indirect and remote measurement techniques often lack the desired accuracy.

Attempts have been made to directly measure drilling parameters and/or tubular make-up and break-out parameters, but such attempts generally require expensive and impractical modifications of the torque drive system pipe handler system. For example, as shown in FIG. 1, a conventional well drilling system may include separate upper and lower blowout preventer valves (A and B) located between a torque drive system (C) and a back-up clamp (D) as well as a measurement device (E) attached below the back-up clamp (D), an associated saver sub (F), and a tubular string (G). This configuration prevents normal use and operation of the pipe handler backup clamp for making and breaking tubular connections, and additional tubular make-up/break-out equipment has to be used to make or break connections below the measurement device (E).

Other prior art systems attempt to directly measure drilling parameters with sensors applied directly to an IBOP valve, but this configuration does not permit sensing of certain drilling parameters below the IBOP valve, which is important when the IBOP valve is closed.

SUMMARY

The present invention solves the above-described problems and other problems by providing a more effective way to measure drilling parameters, casing running parameters, and/or tubular make-up and break-out parameters of a well drilling system without requiring expensive and impractical modifications of the torque drive system's pipe handler assembly and without connecting sensors directly to an IBOP valve. The invention accomplishes these and other objectives with one or more IBOP valves and a stand-alone measurement device that are configured and positioned so as to fit between the constrained space between a torque drive system and a back-up clamp.

A well drilling system constructed in accordance with an embodiment of the invention comprises a torque drive system; a tubular string positioned below and rotated by the torque drive system; a back-up clamp assembly positioned between the torque drive system and the tubular string for coupling with and supporting one end of the tubular string; at least one IBOP valve positioned between the torque drive system and the back-up clamp assembly; and a measurement device for measuring drilling parameters or tubular make-up and break-out parameters of the drill, landing, and casing strings during a drilling and/or casing running operation.

The measurement device may measure or otherwise monitor any drilling parameter, tubular make-up parameter, and/or tubular break-out parameter and is separate from the IBOP valve. The measurement device is connected below the IBOP valve but above the back-up clamp assembly and above the tubular string. This arrangement allows the back-up clamp and an associated saver sub to be used to make or break tubular connections without modifying the torque drive system or pipe handler assembly or otherwise interfering with the IBOP valve and measurement device. This configuration also permits the measurement device to measure drilling parameters and/or tubular make-up and break-out parameters below the IBOP valve so that parameters such as internal fluid pressures may be monitored even when the IBOP valve is closed to allow for safe and controlled re-opening of the IBOP valve after a high pressure situation.

In other embodiments, the well drilling system may include a second IBOP valve below the first IBOP valve. The measurement device may be attached below both IBOP valves or between the two IBOP valves. Two or more IBOP valves may be integrated into a single multi-valve body to further reduce the stack-up height. This allows the IBOP valves and the measurement device to fit between the torque drive system and the back-up clamp without requiring expensive and impractical modifications of the torque drive system or back-up clamp.

This summary is provided to introduce a selection of concepts in a simplified form that are further described in the detailed description below. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other aspects and advantages of the present invention will be apparent from the following detailed description of the embodiments and the accompanying drawing figures.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

Embodiments of the present invention are described in detail below with reference to the attached drawing figures, wherein:

FIG. 1 is an elevational view of portions of a prior art well drilling system;

FIG. 2 is an exploded elevational view of portions of a wireless information technology system constructed in accordance with embodiments of the present invention;

FIG. 3 is an elevational view showing the components in FIG. 2 assembled;

FIG. 4 is an elevational view showing the components of FIGS. 2 and 3 coupled with other components of the well drilling system and assembled in accordance with embodiments of the present invention;

FIG. 5 is a schematic diagram of another embodiment of the present invention in which a pair of IBOP valves and a measurement device are integrated into a single body;

FIG. 6 is a schematic diagram of yet another embodiment of the present invention in which a pair of IBOP valves and a measurement device are integrated into a single body; and

FIG. 7 is an elevational view showing the components of FIGS. 5 and 6 coupled with other components of the well drilling system and assembled in accordance with embodiments of the present invention.

The drawing figures do not limit the present invention to the specific embodiments disclosed and described herein. The drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the invention.

DETAILED DESCRIPTION

A well drilling system constructed in accordance with embodiments of the present invention provides a more effective way to measure drilling parameters, tubular make-up parameters, and/or break-out parameters without requiring expensive and impractical modifications of the torque drive system or the back-up clamp assembly, and without connecting sensors directly to an IBOP valve. The invention accomplishes this with one or more IBOP valves and a stand-alone measurement device that are configured and positioned so as to fit between the constrained space between a torque drive system and a back-up clamp assembly. The measurement device is connected below at least one IBOP valve but above a tubular string and the back-up clamp assembly. This arrangement allows the back-up clamp and an associated saver sub to be used to make or break tubular connections without modifying or otherwise interfering with the IBOP valve and measurement device. This configuration also permits the measurement device to measure drilling parameters and/or tubular make-up and break-out parameters below the IBOP valve so that parameters such as internal fluid pressures may be monitored even when the IBOP valve is closed to allow for safe and controlled re-opening of the IBOP valve after a high pressure situation.

Specific embodiments of the well drilling system will now be described with reference to the attached drawing figures. A well drilling system 10 constructed in accordance with one embodiment of the invention is shown in FIGS. 2-4 and broadly comprises a torque drive system 12; a tubular string 14; a back-up clamp assembly 16; an IBOP valve module 18; and a measurement device 20. The well drilling system 10 may also comprise other conventional components such as a derrick for supporting the torque drive system and tubular string, a pumping system for pumping fluids through the tubular, a hoisting system for raising and lowering the tubular string, and various control devices which will not be described in detail herein.

The torque drive system 12 may be a top drive system or any other system or device capable of rotating the tubular string 14 and its associated drill bit 24. As illustrated in FIG. 4, an embodiment of the torque drive system 12 includes a rotating shaft 22.

The tubular string 14 is directly or indirectly rotated by the torque drive system 12 and includes the drill bit 24 or other device for boring into a ground surface. The tubular string 14 may be formed from any number of tubulars or pipes or conduits joined by threaded connections, flanged connections, pinned connections, splined connections, or other removable connections. In preferred embodiments, the tubular string 14 is hollow so that drilling fluids may be passed though it and into a well.

The back-up clamp assembly 16 is part of a larger pipe handler assembly 26 and is positioned below the IBOP valve module 18 and the measurement device 20 but above the tubular string 14. In some embodiments, the back-up clamp 16 secures a saver sub 28, which may be used to cross-over from the measuring device 20 to the tubular string 14. The saver sub 28 protects the threaded connection of the measuring device 20, and allows connection cross-over from the measuring device 20 connection to the specific tubular string 14 connection of the tubulars used in the tubular string 14.

The IBOP valve module 18 is positioned between the rotating shaft 22 of the torque drive system 12 and the back-up clamp assembly 16. The IBOP valve module 18 functions to isolate pressure in the tubular string should a high pressure situation inside of the tubular string occur. In addition the IBOP valve can be used as a “mud saver”. As best shown in FIGS. 2 and 3, an embodiment of the IBOP valve module 18 includes two IBOP valves, an upper IBOP valve 30 and a lower IBOP valve 32, both integrated in a single multi-valve body 34. An embodiment of the multi-valve body 34 is a tubular with a threaded upper end 36 (internal or external thread) for engaging complimentary threads on the shaft 22 of the torque drive system 12 and a threaded lower end 38 (internal or external thread) for engaging complimentary threads on the measurement device 20. The IBOP valves 30 and 32 may be ball-type valves or any other type of fluid-regulating valves.

The measurement device 20 measures or otherwise monitors drilling parameters and/or tubular make-up and break-out parameters such as the torque and speed exerted on the drill bit 24, internal fluid pressures in the tubular string 14, tubular string temperature, vibration, and tension and compression and may transmit signals representative of such measurements to an internal or external data acquisition, and/or data storage, and/or data processing system, and/or data communications system. Importantly, the measurement device 20 is positioned between the IBOP valve module 18 and the back-up clamp assembly 16, the advantage of which if discussed below.

An embodiment of the measurement device includes a sub body 42 and a housing 40. The housing 40 may be comprised of one or more housing sections to protect the measurement components. In a preferred embodiment, the housing 40 comprises a lower housing 48 and an upper housing 46. One or more sensors, such as a torque sensor, a tension/compression sensor, a vibration sensor, a temperature sensor, a drilling fluid pressure sensor, an acceleration sensor, a resonance sensor, a speed sensor, a drilling fluid flow sensor, a displacement sensor, and/or a drilling fluid level sensor are mounted inside the housing 40 and/or onto the sub body 42. These are merely examples of sensors that may be used with the present invention. Any existing or future designed sensor that is useful in well drilling operations and related fields can be incorporated into the present invention. The upper end of the sub body 42 is threaded for engaging complimentary threads on the lower end 38 of the IBOP valve module 18, and the lower end of the sub body 42 is threaded for engaging complimentary threads on the saver sub 28.

Because the measurement device is connected below the IBOP valve module 18 and above the back-up clamp assembly 16 and tubular string 14, the saver sub 28 may be used to make or break tubular string connections without modifying or otherwise interfering with the IBOP valve module 18 and the measurement device 20. This configuration also permits the measurement device 20 to measure drilling parameters and/or tubular make-up and break-out parameters below the IBOP valve module 18 so that parameter such as internal fluid pressures may be monitored even when the IBOP valve is closed.

A well drilling system 10A of FIG. 7 constructed in accordance with another embodiment of the invention is shown in FIGS. 5-7, with components similar to those in the embodiments of FIGS. 2-4 labeled with the same numerals followed by A. The system 10A comprises a torque drive system 12A; a tubular string 14A; and a back-up clamp assembly 16A. These components are essentially the same as the like-numbered components described above and will therefore not be described in detail again.

As best illustrated in FIGS. 5 and 6, the well drilling system 10A also comprises an integrated IBOP valve and measurement device module 50A that incorporates upper and/or lower IBOP valves 30A, 32A and a measurement device 20A in a single body to further reduce the stack-up height of a portion of the well drilling system. The integrated IBOP valve and measurement device module 50A is positioned between the rotating shaft 22A of the torque drive system 12A and the back-up clamp assembly 16A.

The integrated IBOP valve and measurement device module 50A functions to isolate pressure in the tubular string 14A should a high pressure situation inside of the tubular string occur. In addition the IBOP valves 30A or 32A can be used as a “mud saver”. The measurement device 20A measures or otherwise monitors drilling parameters and/or tubular make-up and break-out parameters such as the torque and speed exerted on the drill bit 24A, internal fluid pressures in the tubular string 14A, temperature, vibration, and tension and compression and may transmit signals representative of such measurements to an external data acquisition, and/or data storage, and/or data processing system.

In the integrated IBOP valve and measurement device module 50A, the measurement device 20A may be positioned below the two IBOP valves 30A, 32A as depicted in FIG. 5 or between the IBOP valves as depicted in FIG. 6. When positioned below both IBOP valves as depicted in FIG. 5, the measurement device 20A can monitor parameters in the tubular string when both IBOP valves are closed. When positioned between the IBOP valves as depicted in FIG. 6, the measurement device can monitor parameters in the tubular string when the upper IBOP valve 30A is closed but the lower valve 32A is open.

An embodiment of the integrated IBOP valve and measurement device module 50A which houses the valves 30A and/or 32A and measurement device 20A is a tubular with a threaded upper end 36A for engaging complimentary threads on the shaft 22A of the torque drive system 12A and a threaded lower end 38A for engaging complimentary threads on the saver sub 28A.

Because the integrated IBOP valve and measurement device module 50A is connected below the torque drive system 12A but above the back-up clamp assembly 16A and tubular string 14A, a saver sub 28A may be used to make or break tubular connections without modifying or otherwise interfering with the IBOP valves and the measurement device or the pipe handler assembly 26A.

The well drilling system 10A may also comprise other conventional components which will not be described in detail herein such as a derrick for supporting the torque drive system and tubular string, a pumping system for pumping drilling fluids down a bore hole, a hoisting system for raising and lowering the tubular string, and various control devices.

Additional Considerations

In this description, references to “one embodiment,” “an embodiment,” or “embodiments” mean that the feature or features being referred to are included in at least one embodiment of the technology. Separate references to “one embodiment,” “an embodiment,” or “embodiments” in this description do not necessarily refer to the same embodiment and are also not mutually exclusive unless so stated and/or except as will be readily apparent to those skilled in the art from the description. For example, a feature, structure, act, etc. described in one embodiment may also be included in other embodiments but is not necessarily included. Thus, the current technology can include a variety of combinations and/or integrations of the embodiments described herein.

Although the present application sets forth a detailed description of numerous different embodiments, the legal scope of the description is defined by the words of the claims set forth at the end of this patent and equivalents. The detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical. Numerous alternative embodiments may be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims.

Throughout this specification, plural instances may implement components, operations, or structures described as a single instance. Although individual operations of one or more methods are illustrated and described as separate operations, one or more of the individual operations may be performed concurrently, and nothing requires that the operations be performed in the order illustrated. Structures and functionality presented as separate components in example configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements fall within the scope of the subject matter herein.

As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.

As used herein, the term “tubular” means any type of tubular used in the well drilling or well construction process, including, but not limited to drill pipe, casing, tubing, drill string, landing string, bottom hole assembly, subs, etc. All the above terms may be used interchangeably and shall have the meaning of “tubular”.

The patent claims at the end of this patent application are not intended to be construed under 35 U.S.C. § 112(f) unless traditional means-plus-function language is expressly recited, such as “means for” or “step for” language being explicitly recited in the claim(s).

Although the invention has been described with reference to the embodiments illustrated in the attached drawing figures, it is noted that equivalents may be employed and substitutions made herein without departing from the scope of the invention as recited in the claims.

Having thus described various embodiments of the invention, what is claimed as new and desired to be protected by Letters Patent includes the following: 

1. A well drilling system comprising: a torque drive system including a rotatable output shaft; a tubular string positioned below the torque drive system and rotated by the output shaft; a back-up clamp assembly positioned between the torque drive system and the tubular string for coupling with and supporting one end of the tubular string; a first blow-out preventer valve removably connected between the torque drive system and the back-up clamp assembly; and a measurement device removably connected below the first blow-out preventer valve and above the back-up clamp assembly for measuring parameters during drilling operations, casing running operations, or tubular make-up and break-out operations.
 2. The well drilling system of claim 1, further comprising a second blow-out preventer valve removably connected between the first blow-out preventer valve and the back-up clamp assembly.
 3. The well drilling system of claim 2, wherein the measurement device is removably connected below both the first blow-out preventer valve and the second blow-out preventer valve and above the back-up clamp assembly.
 4. The well drilling system of claim 2, wherein the measurement device is removably connected below the first blow-out preventer valve and above the second blow-out preventer valve.
 5. The well drilling system of claim 1, wherein the measurement device includes one or more sensors selected from the group consisting of a torque sensor, a tension/compression sensor, a vibration sensor, a temperature sensor, a drilling fluid pressure sensor, an acceleration sensor, a displacement sensor, a rotational speed sensor, a drilling fluid flow sensor, a rotational alignment sensor, and a turns counter.
 6. The well drilling system of claim 2, wherein the first and second blow-out preventer valves are integrated in a single unitary multi-valve body.
 7. The well drilling system of claim 6, wherein the measurement device is removably connected between the multi-valve body and the back-up clamp assembly.
 8. The well drilling system of claim 6, wherein the measurement device is integrated in the multi-valve body below the second blow-out preventer valve.
 9. The well drilling system of claim 6, wherein the measurement device is integrated in the multi-valve body between the first and second blow-out preventer valves.
 10. The well drilling system of claim 3, wherein the measurement device includes a tubular section joined by a protective housing and one or more sensors selected from the group consisting of a torque sensor, a tension/compression sensor, a vibration sensor, a temperature sensor, a drilling fluid pressure sensor, an acceleration sensor, a displacement sensor, a rotational speed sensor, a drilling fluid flow sensor, a rotational alignment sensor, and a turns counter.
 11. The well drilling system of claim 10, wherein the upper tubular section is removably connected for engaging complimentary connection on a lower end of the second blow-out preventer valve.
 12. The well drilling system of claim 11, wherein the lower tubular section is removably connected for engaging complimentary connection on a saver sub or tubular string.
 13. A well drilling system comprising: a torque drive system including a rotatable output shaft; a tubular string positioned below the torque drive system and rotated by the output shaft; a back-up clamp assembly positioned between the torque drive system and the tubular string for coupling with and supporting one end of the tubular string; a multi-valve body positioned between the torque drive system and the back-up clamp assembly, the multi-valve body incorporating both a first blow-out preventer valve and a second blow-out preventer valve in a single unitary housing; and a measurement device connected below the multi-valve body and above the back-up clamp assembly for measuring drilling parameters during a drilling operations, casing running operations, or tubular make-up and break-out operations.
 14. The well drilling system of claim 13, wherein the measurement device includes one or more sensors selected from the group consisting of a torque sensor, a tension/compression sensor, a vibration sensor, a temperature sensor, a drilling fluid pressure sensor, an acceleration sensor, a displacement sensor, a rotational speed sensor, a drilling fluid flow sensor, a rotational alignment sensor, and a turns counter.
 15. The well drilling system of claim 13, wherein the measurement device is removably connected below the multi-valve body.
 16. The well drilling system of claim 13, wherein the measurement device includes a tubular section joined by a protective housing and one or more sensors selected from the group consisting of a torque sensor, a tension/compression sensor, a vibration sensor, a temperature sensor, a drilling fluid pressure sensor, an acceleration sensor, a displacement sensor, a rotational speed sensor, a drilling fluid flow sensor, a rotational alignment sensor, and a turns counter.
 17. The well drilling system of claim 13, wherein the upper tubular section is removably connected for engaging complimentary connection on a lower end of the multi-valve body.
 18. The well drilling system of claim 17, wherein the lower tubular section is removably connected for engaging complimentary connection on a saver sub or tubular string. 